38410-94552 Suzuki PTT RELAY ASSEMBLY

2. Turn the crankshaft until two pistons are at bottom center. Remove connecting rod caps (1) from the two connecting rods.3. Put tape or pieces of rubber hose over the threads of the connecting rod bolts. This will prevent damage to the crankshaft during removal of the pistons.
Do not let the connecting rods hit the bottom edge of the cylinder liners or the crankshaft during removal and installation of the pistons.
TYPICAL EXAMPLE4. Push the piston and connecting rod away from the crankshaft until the piston rings are above the cylinder liner. Remove the two pistons (2) and the connecting rods from the engine.5. Keep each connecting rod cap with its respective connecting rod and piston. Put identification on each connecting rod as to its location in the engine for use at assembly of the engine.6. Do Steps 2 through 5 for the remainder of the pistons.Install Pistons
1. Turn the crankshaft until the bearing journals for the pistons to be installed are at bottom center.2. Put clean engine oil on the crankshaft journals and on the inside of the cylinder liners. Put clean engine oil on the piston rings and connecting rod bearings.3. Move the rings on the piston until the ring openings are approximately 90° apart.
Never install the ring compressor on the piston unless the cylinder is used as a guide. Damage to the piston rings can be the result.
TYPICAL EXAMPLE4. Put ring compressor (A) in position on the cylinder liner. Put the connecting rod and piston in position in the same cylinder liner from which it was removed and into the ring compressor. Make sure the "V" mark on the piston is in alignment with the "V" mark on the cylinder block.5. Push the piston into place as the connecting rod is put into position on the crankshaft. 6. Put clean engine oil on bearings, bolt threads and surfaces of the nuts that make contact with the connecting rod caps. Put caps (1) in position on the connecting rods and install the nuts. Tighten the nuts to a torque of 30 3 lb.ft. (40 4 N m). Put a mark on each nut and the end of each bolt. Tighten the nuts 90° more.
When connecting rod caps are installed, make sure the number on the side of the cap is next to and respective with the number on the side of the connecting rod.
7. Follow the same above procedure for installation of the remainder of the pistons.end by:a) install oil pan plateb) install cylinder headDisassemble Pistons
start by:a) remove pistons 1. Remove rings from piston with tool (A). 2. Remove snap ring (3), piston pin (1) and connecting rod (2) from piston.Assemble Pistons
If a replacement of the rod pin is made, use a pin boring machine to make the bearing the correct size. 1. Install rod on piston with bearing tab groove (2) and number identification on the same side as the "V" mark (1) on top of piston.2. Install piston pin and snap rings. 3. When the old pistons are used, clean the piston grooves with tool (A) before new piston rings are installed.4. Install rings on piston with tool (B). The ring openings must be 90° apart.end by:a) install pistons